EP3999458A1

EP3999458A1 - Range sensing conveyor package management system for measuring and controlling density of parcels on a conveyor

Info

Publication number: EP3999458A1
Application number: EP20840370.9A
Authority: EP
Inventors: Steven Vann Schroader; Gus NOWOTNY
Original assignee: Fives Intralogistics Corp
Current assignee: Fives Intralogistics Corp
Priority date: 2019-07-16
Filing date: 2020-07-16
Publication date: 2022-05-25
Also published as: WO2021011833A1; CN114341032B; JP7397162B2; EP3999458A4; JP2022540937A; WO2021011833A4; CN114341032A

Abstract

The present invention relates to the field of using different sensing and detection methods to determine parcel flow density 1D lineal, 2D area or 3D volumetrically on a selected section of a feed conveyor and receiving conveyor and adjusting conveyor speed ratios proportioned according to ratio of desired density to current density to increase the density or volume of parcels in a selected area of the receiving conveyor.

Description

RANGE SENSING CONVEYOR PACKAGE MANAGEMENT SYSTEM FOR

MEASURING AND CONTROLLING DENSITY OF PARCELS ON A CONVEYOR

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority from U.S. Provisional Application Serial No. 62/874,902 filed on July 16, 2019 which is incorporated by reference herein in its entirety.

TECHNICAL FIELD

The present invention relates to the field of using different sensing and detection methods to detect and control parcel flow density on conveyors. BACKGROUND OF THE INVENTION

Conveying systems often serve the function of aligning and spacing articles on the conveying system to be processed by a downstream sorting system. Conventional conveyance systems typically involves controlling the articles in such a way that the articles leaving the induction subsystem have gaps between them or beside them that are close to a desired length. The desired gap may be variable depending upon the length and/or width of one or more of the pair of articles that define the gap, or the desired gap may be constant. Regardless of the criteria used to determine the length of the desired gap, the gap serves the purpose of facilitating the sorting of the articles. Sorting systems often function more effectively if the articles being sorted have a certain minimum gap between them. However, gaps exceeding this minimum will generally decrease the throughput of the conveying system. It is desirable to create gaps that balance sorting criteria while maximizing the throughput to the sorting and singulator apparatus; however, at the point of induction where the parcels are fed onto a plurality of conveyors from various feed points such as truck unloading stations, maximum efficiency is achieved by moving as many parcels as possible on a given area of the conveyor. Due to the variability of the amount of product coming in on various feed belts, imbalances occur at different merge areas in the conveying system causing large open spots on tbe collector belt, singulator belt and sorting area. This fact causes inefficiency, an unnecessary investment in equipment, and a degradation of overall throughput to the sorter. Conventional flow management systems count packages and /or control the speed of conveyors to orient or single packages and create a desired minimum gap there between for processing. Examples of these devices is set forth in the following patent and/or publications.

US Patent No. 5165520 teaches a conveying system which spaces parcels on a belt and includes a camera system which recognizes overlapping or crowding of parcels and diverts the offending parcels. US Patent No. 8061506 teaches merging articles onto conveyors using information gathered from optical sensors or cameras to recognize or create an gas on a collector belt and fill these gaps with a package from an feed belt; however, Schafer does not discuss the method of processing information from cameras or optical sensors to control the concentration of same. Publication (WO200066280) describes a system using a camera to determine the number of parcels and uses this information to control the speed conveyors such as a parcel feeder conveyor, acceleration conveyor, buffer conveyor, singulator and transportation conveyor; however, the reference does not teach nor suggest the idea of controlling the speed of conveyance in order to maximize the area covered on the conveyor as a function of occupancy on a collector or just prior to singulator. US Patent 6471044 teaches that images are transferred to a control system where the images are interpreted to determine the number of packages and the average size of the packages to regulate the speed of the parcel feeder conveyor, buffer conveyor, acceleration conveyor, singulator, and transport conveyor, but not the density of the packages on a given area of the conveyor. U.S. Patent 5141097 teaches analysis of an image supplied by a camera to provide an indication of the number of packages present in this image and increase the conveyor speed to obtain the desired throughput. US Patent 6401936 teaches a detection system for monitoring the stream of articles and identifying and/or tracking individual items passing through the system used in conjunction with a singulator, hold-and-release or strip conveyor downstream from the coarse singulator wherein the control system is utilized in connection with the detection system to regulate the flow of articles through the system by increasing the speed of the conveyor. Conventional systems utilize methods of either counting carton feet or parcels released from the container unload conveyors, and adjusting the speeds of the unload conveyors to maintain the input flow at a manageable level for the singulator and sorter. The goal is to keep the system fed, without over-feeding. Current FDXG systems have sorter capacity of 12,150 parcels per hour (pph) with a 12 inch gap at 540 feet per minute ( fpm), and with a 20 inch average. The result is that the system throughput efficiency is limited, and typical sustained performance capability is only expected to be about 60% of sorter capacity. There is a need for a control system to maximize the occupancy and density of packages on a given area of a receiving conveyor for unloading packages and a mechanism for sensing physical characteristics of packages from a transport such as rail car, airplane, ship, or truck in order to send the article to the appropriate sorting system and controlling the transfer speed of the articles.

SUMMARY OF THE INVENTION

The present invention relates to the field of using different sensing and detection methods to determine parcel flow density ID lineal, 2D area or 3D volumetrically on a selected section of a feed conveyor and receiving conveyor and adjusting conveyor speed ratios proportioned according to ratio of desired density to current density to increase the density or volume of parcels in a selected area of the receiving conveyor.

Density measuring apparatus recognizes and maximizes conveyor surface area utilization. Sensing and detection apparatus determine parcel flow density ID lineal, 2D area or 3D volumetrically on a selected area of a conveyor and adjust feed and receiver conveyor speed ratios proportioned according to ratio of desired density to current density to increase the density or volume of parcels in a selected area enhancing the performance and throughput of conveyor systems. Sensing and/or detection apparatus are positioned at flow entry points or transition points between the feeder and receiver conveyor. A control algorithm recognizes individual items area, volume or density and the rate of speed or velocity at which individual objects are passing on a selected area of the feed conveyor and receiving conveyor surface and the area utilization of the feed conveyor and receiving conveyor to maintain a desired density of packages on the receiving conveyor surface. The bulk parcel flow management system comprises or consists of a density based detection system that recognizes belt area utilization, and parcel count. The system density detection devices positioned at flow entry points and at the singulator. The control algorithm requires recognition of individual items and the rate at which individual objects are passing, and the area utilization of the collector belt. Average parcel size (area or volume) including length, width, and height can be considered as well. Moreover, the density or weight of a parcel can be considered in conveyor surface area utilization. The present invention provides a means for increasing conveyor area and/or volume and/or density by controlling feed and receiving conveyor movement defined as speed“velocity” to fill available space on the receiving collector conveyor. The conveyor package management system may also identify, locate, or trace a package, parcel, or other item on the conveyor by its digital image, scanner code, or footprint.

The present invention comprises or consists of an apparatus for detecting and measuring the density of parcels on a selected section of a conveying surface, comprises or consists of a plurality of photo eyes for creating a table of sensing range, wherein each photo eye has two outputs and each one is independently adjustable to obtain two different ranges. The plurality of photo eyes are installed on a first side and an opposing second side of a selected section of a feed conveyor having a conveying surface extending to a receiving conveyor having a conveying surface at a selected distance from an discharge end of the feed conveyor and a receiving end of the receiving conveyor. A virtual encoder is programmable to produce a pulse at selected intervals of the feed conveyor. An array includes a plurality of array elements, each of the array elements representing one pulse of the virtual encoder defining a selected length of the selected distance. A programmable logic controller having an algorithm for calculating the average measured occupancy of the array representing a percentage of fullness of the receiving conveyor.

The method of detecting and measuring the density of parcels on a selected section of a conveying surface, comprises or consists of the steps of creating a table of sensing range with a plurality of photo eyes, wherein each photo eye has two outputs and each one is independently adjustable to obtain two different ranges. The plurality of photo eyes is installed on a first side and an opposing second side of a selected section of a feed conveyor and a receiving conveyor at a selected distance from an discharge end of the feed conveyor and a receiving end of the receiving conveyor. A pulse is produced at selected intervals along the selected section of the conveying surface with a programmable virtual encoder. An array is formed including a plurality of array elements, each of the array elements representing one pulse of the virtual encoder defining a selected length of the selected distance. The average measured occupancy of the array is calculated by determining the combination of photo eye outputs blocked when an encoder pulse occurs representing a percentage of fullness of the receiving conveyor with a programmable logic controller using an algorithm. The measured occupancy to a desired occupancy of the feed conveyor is compared to the receiving conveyor. A speed ratio is calculated by dividing the desired occupancy by the measured occupancy. The speed of the feed conveyor, the receiving conveyor, or the feed conveyor and the receiving conveyor is regulated to obtain a desired occupancy on the receiving conveyor.

In addition to range sensing photo eyes, sensors may include a opposing or left and right range sensor photo eyes, vibration sensors, heat detection sensors, weight sensors, and smart light stacks in electrical communication with the PLC or computer.

It is an object of this invention to provide a range sensing conveyor package management system which includes photo eyes which monitor the packages at the merge areas of the feed conveyors, all along the collector conveyor, the singulator conveyor and the sorter, identifying areas of low density and controlling the activation and speed of selected conveyors to increase the density of items of a given area of a conveyor.

It is an object of this invention to provide a range sensing conveyor package management system to utilize an algorithm and software in a computer for computing the open or unused area on the conveyors by comparing the area covered by packages on conveyors to the open area based on digital data analysis of the information coming from each of the photo eyes monitoring the conveyors.

It is an object of this invention to provide a range sensing conveyor package management system wherein the photo eyes are interfaced with a computer which assembles the data from the photo eyes and outputs speed signals for selected feed conveyors in the system to fill in the large space areas on the collector conveyor with parcels to achieve a selected density of a particular area at 60% or greater.

It is an object of this invention to provide a range sensing conveyor package management system which determines the percentage of surface area of the collector conveyor, singulator conveyor, and other conveyors which is covered by packages, parcels, bags, envelopes, boxes, or other articles.

It is an object of this invention to provide a range sensing conveyor package management system which counts and identify the number of items contained on a conveyor.

It is an object of this invention to provide a range sensing conveyor package management system to identify, located, or identify a package, parcel, or other item on the conveyor by its digital image or footprint.

It is an object of this invention to provide a range sensing conveyor package management system which regulates input flow to a conveyor system where a photo eye is placed at each source of input to a collector conveyor, allowing control of the speed of each input conveyor with respect to the speed of the collector conveyor to the maximize the flow of packages through the system. It is an object of this invention to provide a range sensing conveyor package management system which forces via friction, skewed rollers, belts, or incline planes, packages to one side of a collector conveyor and causes subsequent feed conveyors to add packages to the open area beside those packages already present on the collector conveyor.

It is an object of this invention to provide a range sensing conveyor package management system which recognizes the number of objects, the average size of the objects, and the area utilization of a conveyor.

It is an object of this invention to provide a vision based system used to determine the percentage surface area coverage of a singulator device. It is an object of this invention to provide a vision based system used to count the number of items contained on a conveyor.

It is an object of this invention to provide a vision based system used to regulate input flow to a conveyor system, where a photo eyes are placed at each source of input flow, allowing control of each input, in respect of the maximum allowable input flow to the system.

It is an object of this invention to provide a vision based system to recognize the number of objects, average size of the objects, and area utilization of a conveyor.

It is an object of this invention to provide a range sensing system that determines fullness of a conveyor system accumulation area, and also, more specifically, for fullness of a parcel singulator. It is an object of the present invention optimize to cover maximum amount of surface of singulator.

It is an object of the present invention to provide a vision based flow management system that includes a photo eye and computer processor and interface to define and control and integrate with a conveyor control system via Ethernet, WIFI, bluetooth, and other smart electronic devices such as phones, tablets, laptop computers and other visual aid computer based devices capable of communicating with a computer system.

The present invention includes a novel method of managing bulk parcel flow with a range sensing management system, comprising or consisting of the steps of: selecting a transition zone between a feed conveyor and a receiving conveyor each one having independent drive motors; selecting a photo eye field of view of the selected transition zone; addressing an IP address to each photo eye; setting an inline feeding conveyor speed to achieve a desired conveyor area utilization on a down stream receiving conveyor where V is velocity (conveyor speed), DO is Desired Occupancy, RCO is Receiving Conveyor Occupancy, and FCO is Feeding Conveyor Occupancy wherein occupancy comprises conveyor area, conveyor volume, or conveyor density); selecting a percentage of photo eye field of view; selecting a percentage of the feeding conveyor occupancy defined zone; selecting a percentage of the receiving conveyor occupancy defined zone; selecting a percentage of the desired occupancy after the merger; feeding parcels to the receiving conveyor occupancy defined zone; conveying parcels toward a desired occupancy zone at a selected position; and merging the parcels at a transition section between the feeding conveyor and the receiving conveyor.

Apparatus and methods used for conveying parcels and controlling the speed and directions of parcels on conveyors is disclosed in Applicant’s U.S. Patent 10,427,884 which issued on October 1, 2019 from U.S. Application Serial No. 15/977,224 filed on May 11, 2018 for a Vison Based Conveyor Package Density Management System; Applicant’s copending U.S. Application Serial No. 16/189,014 for an Off- Loading, Typing and Item Separation System filed on November 13, 2018 both of which are incorporated by reference herein in its entirety. Applicant’s prior patents describe camera based vision density management system, whereas the instant invention provides a more economic alternative based on range sensing photo eyes to measure parcel density and position as opposed to cameras.

Other objects, features, and advantages of the invention will be apparent with the following detailed description taken in conjunction with the accompanying drawings.

BRIEF DESC RIPTION OF THE DRAWINGS

A better understanding of the present invention will be had upon reference to the following description in conjunction with the accompanying drawings in which like numerals refer to like parts throughout the views wherein: Figure 1 depicts a top view of a conveyor surface wherein opposing range sensing photo eyes are installed at selected intervals on both sides of a conveyor section near the exit end creating a table of sensing or detection ranges;

Figure 2 shows a density measurement method using range sensing photo eyes to output an actual analog distance using a sensor with analog output where a true distance from the edge of the belt to the sensed parcel is known and a distance sensing photo eye on both sides of the belt is used to negate the effect of parcels justified to one side; and

Figure 3 shows the architecture for IO-Link based range sensing photo eyes for area;

Figure 4 is a perspective view of a range sensing based conveyor package management system of the present invention showing the photo eye field of view of the bulk parcel flow management system where the inline conveyor speed is set to achieve a desired conveyor area utilization on a down stream conveyor including the percentage of photo eye field of view, the percentage of the feeding conveyor occupancy defined zone, the percentage of the receiving conveyor occupancy defined zone, and the percentage of the desired occupancy after the merger;

Figure 5 is a perspective view of a section of a conveyor system as applied of a linear parcel singulator showing the feed conveyors and receiving conveyors and singulator wherein the roller and belt conveyors utilize independent motors to convey, arrange, and separate parcels and that the principle of the conveyor area utilization, and parcel count utilizing a system with range sensing photo eyes positioned at flow entry points of selected conveyors can be controlled to efficiently feed a singulator or other sorting device;

Figure 6 shows the range sensing photo eye field of view of the transition section of a feed conveyor and receiving conveyor wherein each one of a plurality of range sensing photo eyes provide a field of view to define a feeding conveyor occupancy zone, and receiving conveyor occupancy defined zone at the transition point of merger of the upstream and downstream conveyors;

Figure 7 is a perspective view of a field of detection of both a skewed roller section of the conveyor and a belt section of the parallel and adjacent recirculating belt;

Figure 8 is a top view showing the merger of a side transfer feed conveyor with an intersecting collector conveyor wherein the rate of speed of the conveyors is set to achieve a desired conveyor area utilization on the downstream portion of the collector conveyor, based on a photo eye sensing range of the intersection based on the receiving conveyor occupancy defined zone, feeding conveyor occupancy defined zone and the desired occupancy after the merger;

Figure 9 is a schematic showing the range sensing parcel density flow management system applied to a bulk feed system from the trailer dock to the sorter including a control system regulating a plurality of individual inputs based on the conveyor fullness at various positions and the singulator fullness wherein the conveyor speeds are regulated as a fimction of singulator lulness and incoming occupancy just prior to singulator;

Figure 10 shows an oversight configuration window showing the receiving conveyor occupancy zone and feeding conveyor occupancy zone, each one of which can be resized and dragged together or independently moved to a different position or overlapped;

Figure 11 is an overhead view showing the photo eye range sensing parcel flow management system from the trailer unloading feed conveyors through the singulator and including a recirculating loop; Figure 12 shows the feed conveyors merging with the collector conveyor comprising modular sections and photo eye range sensing arrays at the intersection of each conveyor;

Figure 13 is a top view showing a package progressing forward on a feed conveyor parallel to a collector conveyor; Figure 14 is a top view of the conveyor shown in Figure 13 showing a package progressing forward on a feed conveyor parallel to a collector conveyor, wherein a section of the collector conveyor is controlled to allow a space for receiving an article conveyed by the feed conveyor;

Figure 15 is a top view of the conveyor shown in Figure 13 showing a package progressing forward on a feed conveyor parallel to a collector conveyor, wherein an article conveyed by the feed conveyor is disposed into a receiving section of the collector conveyor;

Figure 16 is a top view of the conveyor shown in Figure 13 showing a package progressing forward on a feed conveyor parallel to a collector conveyor, wherein an article conveyed by the feed conveyor is fed into a position preceding a plurality of articles conveyed on the collector conveyor; and

Figure 17 is a top view of the conveyor shown in Figure 13 showing a plurality of packages progressing forward on a collector conveyor, wherein a angled feed conveyor and side feed conveyor are controlled for insertion of a package into a vacant area of the collector conveyor.

DESC RIPTION OF THE PREFERRED EMBODIMENTS

In accordance with the present invention, there is provided a range sensing parcel flow

management system using different sensing and detection methods to determine parcel flow density ID lineal, 2D area or 3D volumetrically on a selected section of a feed conveyor and receiving conveyor and adjusting conveyor speed ratios proportioned according to ratio of desired density to current density to increase the density or volume of parcels in a selected area of the receiving conveyor.

The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms "a," "an," and "the" may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms "comprises," "comprising," "including," and "having," are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.

When an element or layer is referred to as being "on," "engaged to," "connected to," or

"coupled to" another element or layer, it may be directly on, engaged, connected or coupled to

the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being "directly on," "directly engaged to," "directly connected to," or "directly coupled to" another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., "between" versus "directly between," "adjacent" versus "directly adjacent," etc.). As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items.

Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as "first," "second," and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

Spatially relative terms, such as "inner," "outer," "beneath," "below," "lower," "above," "upper," and the like, may be used herein for ease of description to describe one element or feature's relationship to another elements) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as "below" or "beneath" other elements or features would then be oriented "above" the other elements or features. Thus, the example term "below" can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

As used herein, the term“about” can be reasonably appreciated by a person skilled in the art to denote somewhat above or somewhat below the stated numerical value, to within a range of + 10%.

As used herein, the term“parcel” includes articles, envelopes, mail, packages, bags, drums, boxes, or irregular shaped items or conveyed containers.

As used herein the term“range sensing” includes one or more imaging devices including a photo eye, camera, video photo eye, scanner, laser, selected light transmission frequency or wavelength or other pixel detecting and/or digital imaging devices (collectively referred to as photo eyes).

The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout.

In accordance with the present invention, there is provided a parcel flow management system based on a density based range sensing detection system that recognizes belt area utilization and parcel count.

The parcel flow management system comprises or consists of a density based detection system that recognizes conveyor surface area utilization, and parcel count. The detection system sensors are positioned at selected flow entry points across the conveyor. The control algorithm requires recognition of individual items and the rate at which individual objects are passing, and the area utilization of the conveyor surface for increasing conveyor area and controlling density. Average parcel size can be considered as well. The detection package management system may also identify, locate, or trace a package, parcel, or other item on the conveyor by its measurements and at selected positions on the conveyor.

In accordance with the present invention, there is provided a density based detection system conveyor package management system comprising, consisting of , or consisting essentially of a programmable logic controller or computer and sensors detecting parcels or package, a collector“receiver” conveyor including separate sections of the conveyor separately driven by individual motors with individual speed controllers. Selected ones of the sections of the collector conveyor have means such as low friction conveying surfaces such as skewed rollers or high friction conveying surfaces capable of urging a package to a selected side of the collector conveyor. A plurality of feed conveyors include separate sections of the conveyor separately driven by individual motors with individual speed controllers. Range detection sensors measuring the area, volume, or density of items on the conveyor surface leading up to merge areas of each of the feed conveyors with the collector conveyor. The speed of the feed conveyor and collector conveyor leading up to merge areas of each of the collector conveyor is measured, and a control program within the PLC or computer is capable of controlling speeds of the sections of the collector conveyor and of the sections of the feed conveyors based on a calculated amount of free space on a given collector section compared to a footprint of a package on an oncoming feed conveyor. A singulator conveyor may be incorporated within the conveyor system and fed by the collector conveyor.

A typical feed conveyor or collector“ receiving” conveyor includes one or more separate sections of conveyors separately driven by individual motors with individual speed controllers. Selected ones of the sections of the collector conveyor may have low friction conveying surfaces such as skewed rollers arranged in configurations capable of urging a package to a selected side of the receiving collector conveyor and/or include higher friction conveying surfaces such as belts. A plurality of feed conveying surfaces may include separate sections of the conveyor separately driven by individual motors with individual speed controllers.

Detection range devices monitor areas of the collector conveyor leading up to merge areas of each of the feed conveyors with the collector conveyor, detection devices monitoring areas of the feed conveyor leading up to the merging areas of each of the feed conveyors with the collector conveyor. The bulk parcel flow management system including a programmable logic controller or computer as a control program within the computer or PLC capable of controlling the speed’’velocity” of the feed and/or collector “receiving” conveyors or sections of the collector“receiving” conveyor and/or sections of the feed conveyors based on a calculated amount of free space thereon. A given collector section is compared to a footprint of a package on an oncoming feed conveyor. A calculated by photo eyes and virtual encoder creates a pulse at selected intervals to create an array to determine measured occupancy as a percentage of fullness of parcels on the feed conveyor and/or collector“receiving” conveyor.

For example, the current FDXG requirements for a control conveyor of a selected area and speed is 7,500 parcels per hour over 10 minutes, with two (one minute) slices at 8250 parcels per hour,

(7500/12150 = 0.62 = 62% efficiency over 10 min test). The present invention provides a means of controlling the area utilization of the available conveyor surface to obtain an efficiency of up to 75% equivalent to 9,375 parcels per hour for the same conveyor. Moreover, a 15% increase of results in an increase of 8,625 parcels per hour for the range sensing conveyor package management system conveyor with area utilization in accordance with the instant invention.

Range detection devices are positioned at selected individual input points in wired or wireless communication with a PLC or computer including a process control algorithm to recognize incoming flow density, in terms of both belt utilization and throughput rate. These measures can be used to make changes to reduce parcel input flow, and could require stoppage of the feed line, if flow is too sparse or dense.

Similarly, absence of flow could be recognized prompting an increase in speed of a selected input conveyor or input conveyors.

The detection devices can be positioned to view the singulator surface are used in a similar matter to assess the buffer capacity utilization, primarily based on area coverage recognition. This feedback is used to dynamically adapt behavior of feed lines. The use of web cams may provide added benefits in terms of system control room visibility and recordation. Variations in parameters used to tune the system can be evaluated in a more efficient manner. Jams and other system problems are better recognized.

A plurality of range sensing photo eye detection devices in communication with a computer based conveyor package management system includes the number and size of the packages present a given area of an feed conveyor, collector conveyor, and optionally singulator conveyor and sorting conveyor in a package handling system wherein the data is collected and analyzed to measure the available area or space on the conveyors and the density of packages thereon to maximize a desired density of packages on selected conveyors). The number of feed conveyors providing packages and the conveyor speed of each is controlled as a function of occupancy on a collector or just prior to a singulator. The computer feeds the conveyor surface package density information to the conveyor speed controllers to introduce packages from one or more feed conveyors to a collection conveyor wherein packages are detected across an area, volume, or density of the conveyor surface and the speed of selected conveyors is controlled for arrangement of the packages at optimal spacing and to fill an area of the conveyor in the most efficient manner maximizing the density of the packages on a conveyor and throughput of the system and accordingly minimizing the number of conveyors required for the system. When the computer determines there is a enough space on one of the conveyor belts, for example, the collector belt, the computer tells the controller to add a package or packages by causing an feed belt to add a package or packages to the space or vacant area on the collector belt.

An algorithm is used to calculate the“measured Occupancy” whereby the sensing distance represents a percentage of belt coverage. Once the“Measured Occupancy” of the conveyor is calculated, it is compared to the“Desired Occupancy” of the conveyor surface area to determine the speed ratio of the downstream conveyor. The“Speed Ratio” is the Desired Occupancy divided by the Measured Occupancy and the speed at which to command the conveyor is then determined by the following equation where (FPM) is measured in feet per minute:

Speed of Current Conveyor (FPM) = Downstream Speed (FPM) * Speed Ratio ** Power Factor Different sensing methods are used to determine flow density ID lineal, 2D area or 3D

volumetrically on a conveyor and adjusting conveyor speed ratios proportioned according to ratio of desired density to current density to enhance the performance and throughput of conveyor systems.

The range sensing conveyor package management system for measuring and controlling density of parcels on the conveyor present invention uses different sensing and detection methods to determine parcel flow density ID lineal, 2D area or 3D volumetrically on a selected section of a feed conveyor and/or receiving conveyor and adjusting conveyor speed ratios proportioned according to ratio of desired density to current density to increase the density or volume of parcels in a selected area of the receiving conveyor.

The 2D discrete distance measurement method uses SICK WTT190L photo eyes to create a table of sensing ranges. Each photo eye has two outputs, each independently adjustable to obtain two unique ranges. The photo eyes are installed on both sides of the conveyor section at selected distance of about five (5) feet from the exit end of the conveyor as shown in Figure 1. Optionally a plurality of photo eyes may be installed in a bank or array. As shown in Figure 1, a first side 361 of the conveyor having a width of 61 inches includes a photo eye 351 which measures a range across the conveyor of up to 13 inches and the opposing photo eye 362 on the opposing second side 362 of the conveyor measures a distance of up to 48 inches. A photo eye 353 on the first side of the conveyor measures a range across the conveyor of up to 25 inches and the opposing photo eye 364 on the opposing second side of the conveyor measures a distance of up to 36 inches. A photo eye 355 on the first side of the conveyor measures a range across the conveyor of up to 37 inches and the opposing photo eye 366 on the opposing second side of the conveyor measures a distance of up to 24 inches. A photo eye 357 on the first side of the conveyor measures a range across the conveyor of up to 49 inches and the opposing photo eye 358 on the opposing second side of the conveyor measures a distance of up to 12 inches.

A virtual encoder is programmed for the conveyor section to produce a pulse at selected intervals, for example at two inch intervals of belt motion. An array is created to represent the final five feet of the feed conveyor section, plus an additional five feet onto the receiving collector conveyor or downstream conveyor section, or 120 inches. With each element of the array representing a two inch section, or one pulse of the virtual encoder, the total number of array elements at the conveyor transition sixty array elements.

Dependent upon the combination of photo eye outputs blocked when an encoder pulse occurs, a “measured occupancy” value is populated in the current array element. The“measured occupancy” is a percentage of fullness, 0 being an empty belt or no blocked photo eyes, and a 100 being all photo eyes blocked. The photo eyes are re-evaluated at each encoder pulse and the result is populated into the current array position. The overall measured occupancy of the 10 foot section of conveyor (5 feet on the exit of the current belt and 5 feet on the entry of the downstream belt) is found by adding all of the values in the array together, then dividing by the total number of array elements.

The following table describes how the combination of blocked photo eyes yields the proper measured occupancy to populate in the array: Table I

As shown in Table I, the first left side photo eye status is resolved first. Then the second right side photo eye status is resolved to yield the percentage of fullness at the encoder pulse, as represented by the values in the chart. Once the proper combination has been found, the algorithm ends and the resulting value is then placed in the current array element. The algorithm stores the last sixty values, adds them all together, then divides by the total number of array elements to get the average measured occupancy represented as a percentage, ranging from 0 to 100. Note that the“n/a” in the chart above means that condition cannot exist with the photo eye ranges adjusted as shown in the diagram.

Once the measured occupancy of the belt is calculated, it is compared to the“Desired Occupancy” of the belt, which can then be calculated to determine the Speed Ratio of the downstream belt. The “Desired Occupancy” is a configurable parameter. It is expected to be in the range of 30% to 40% but the final value must be determined in the field. The Speed Ratio is the Desired Occupancy divided by Measure Occupancy. So if the Desired Occupancy is 30% and the Measured Occupancy is found to be 70%, then the Speed Ratio is 30/70 or 0.429. The speed at which to command the belt is then determined by the following equation:

Speed of Current Belt(FPM) = Downstream Speed(FPM) * Speed Ratio ** PowerFactor

PowerFill 2D using IO-Link based Analog Distance Sensing Range

The following density measurement method example uses the BALLUFF BOD0020 photo eyes which output an actual analog distance. By using a sensor with analog output, a hue distance from the edge of the belt to the sensed parcel is known. A distance sensing photo eye is still needed on both sides of the belt to negate the effect of parcels justified to one side. The sensing distance is set to a maximum of the conveyor width as shown in Figure 2 wherein LPE1 is designated as 364 and RPE1 is designated as 363.

A virtual encoder is programmed for the conveyor section to produce a pulse at two inch intervals of belt motion. An array is created to represent the final five feet of conveyor section, plus an additional five feet onto the downstream conveyor section, or 120 inches. With each element of the array representing two inches, or one pulse of the virtual encoder, the total number of array elements at the conveyor transition is sixty (60) array elements.

The algorithm to calculate“measured occupancy” is calculated and compared to the "Desired Occupancy" of the belt which can be calculateed to determine the Speed Ratio fo the downstream belt. The sensing distance represents a percentage of belt or "conveyor surface area "coverage. A parcel that is detected at sixty inches will yield a percentage close to 0%, whereas a parcel that is detected 1 or 2 inches will yield a percentage close to 100%. To obtain the“measured occupancy”, a combination of the distances sensed by both photo eyes must be used to generate an accurate occupancy across the belt. This value is calculated at each virtual encoder pulse and placed in the overall measured occupancy array. The photo eyes are re-evaluated at each encoder pulse and the result is populated into the current array position. The overall measured occupancy of the ten foot section of conveyor (five feet on the exit of the current belt and five feet on the entry of the downstream belt) is found by adding all of the values in the array together, then dividing by the total number of array elements. Once the measured occupancy of the belt is calculated, it is compared to the“Desired Occupancy” of the belt, which can then be calculated to determine the Speed Ratio of the downstream belt. The “Desired Occupancy” is a configurable parameter. It is expected to be in the range of 30% to 40% but the final value must be determined in the field. The Speed Ratio is the Desired Occupancy divided by Measure Occupancy. So if the Desired Occupancy is 30% and the Measured Occupancy is found to be 70%, then the Speed Ratio is 30/70 or 0.429. The speed at which to command the belt is then determined by the following equation:

Speed of Current Belt(FPM) = Downstream Speed(FPM) * Speed Ratio **Power Factor

As noted heretofore, a Power Factor can be utilized in the equation above as a configurable parameter and can set how aggressive the Current Belt Speed will go for larger corrections. A large power factor means more aggressive correction. For PowerFill two dimensional area "2D" the power factor is set can be set to 1.

For instance, sensing methods to determine flow density in lineal area, "ID", or in two

dimensional area "2D", or density defined volumetrically "3D", is determined and adjusting conveyor speed ratios proportioned according to ratio of desired density to current density. The analog signal obtained from the photo eyes are the IO-Link, so the main PLC will get the distance information from the photo eyes via Ethernet. The architecture for IO-Link based PowerFill 2D is shown in Figure 3. The IO-Link 365 devices include a left range detect photo eye 366, a right range detect photo eye 367, an optional smartlight stack 368, an optional vibration detection sensor 369, and an optional heat detection sensor 370. It is contemplated that other sensors known in the art may be linked as well.

The IO-Link Master has the following features useful to the PowerFill 2D application:

The IO-Link Master is a field-mounted device. The sensors plug directly into the unit via standard 5-pin Euro-Style cord sets. It connects back to the PLC via Ethernet. It allows the capability to plug in other IO-Link input devices, such as temperature and vibration sensors. It allows the capability to plug in IO-Link output devices, like the SmartLight shown above. The SmartLight can be configured in multiple colors, multiple flashing or static configurations, etc. The sensors have diagnostic capabilities over the IO-Link to the PLC so that a photo eye that is becoming dirty can be annunciated on the HMI (and on the SmartLight). The configuration parameters to set up the devices (such as range and output units) are stored in the PLC so device replacement requires no setup once the device has been replaced.

The parcel flow management system comprises or consists of a density based detection system is compatible with a conveyor system having multiple sections 10 includes a plurality of conveyor modules or sections with belts and/or conveyor rollers for transporting and separating articles such as envelopes, mail, parcels, packages, bags, drums, boxes, or irregular shaped items thereon. As shown, a linear parcel singulator 8 and recirculating conveyor 14 are in flow communication therewith. A plurality of photo eyess provide a filed of view of selected occupancy defined zones such as the transition area 70 or transition point of merger of articles from one conveyor to another. Independent motors drive the conveyor modules or sections creating zones that can be accessed for a particular photo eye via the assigned IP address.

At least one photo eye, camera, video camera or other pixel detecting and/or digital imaging devices is positioned at each individual input point, with a control algorithm to recognize incoming flow density, in terms of both belt utilization and throughput rate. These measures can be used to make changes to reduce parcel input flow, and could require stoppage of the feed line, if flow is too dense. Similarly, absence of flow could be recognized prompting an increase in speed of the input conveyor.

Photo eyess positioned to view the singulator surface are used in a similar matter to assess the buffer capacity utilization, primarily based on area coverage recognition. This feedback is used to dynamically adapt behavior of in-feed lines. The use of web cams provides added benefits in terms of system control room visibility. Variations in parameters used to tune the system can be evaluated in a more efficient manner. Jams and other system problems are beter recognized.

In one preferred embodiment, a range sensing photo eyes and computer based conveyor package management system includes range sensing photo eyess monitoring the number and size of the packages present on the infeed conveyors, collector conveyor, singulator conveyor and/or sorting conveyor in a package handling system wherein the photo eyes data is used to measure the available area or space or volume on the conveyors to maintain a desired density of packages on selected conveyor(s). The conveyor speed is controlled as a function of occupancy on a collector or just prior to a singulator. The computer feeds the information to the conveyor speed controllers to introduce packages from one or more feed conveyors to a collection conveyor wherein packages are detected by one or more photo eyess and the speed of selected conveyors and/or the velocity of the packages or articles is controlled for arrangement of the packages at optimal spacing maximizing the density or volume of the packages on a given conveyor area and throughput of the system and accordingly minimizing the number of conveyors required for the system. When the computer determines there is a enough space on one of the conveyor belts, for example, the collector belt, the computer tells the controller to add a package or packages by causing an infeed belt to add a package or packages to the space or vacant area on the collector belt.

It is contemplated that a line-scan photo eyes having a single row of pixel sensors can be utilized in the instant invention. The lines are continuously fed to a programmable controller, programmable logic controller (PLC), or a computer that joins them to each other and makes an image. Multiple rows of sensors may be used to make colored images, or to increase sensitivity by TDI (Time delay and integration). Traditionally maintaining consistent light over large 2D areas is quite difficult and industrial applications often require a wide field of view. Use of a line scan photo eyes provides even illumination across the“line” currently being viewed by the photo eyes. This makes possible sharp pictures of objects that pass the photo eyes at high speed and be used as industrial instruments for analyzing fast processes. It is contemplated that a 3D photo eyes system utilizing one or more photo eyess or other pixel detecting and/or digital imaging devices may also be used to detect the height of the packages and determine volume density.

The photo eyes based density measurement system recognizes and maximizes belt area utilization of the feed conveyor. A plurality of photo eyess can be positioned at selected points of the feed conveyor and the receiving end of the receiving conveyors. A computer with a control algorithm recognizes individual items area, foot print of the items and the rate at which individual objects are passing, and the area utilization of the feed conveyor. The range sensing photo eyes and computer based conveyor package management system monitor and control the speed of the feed conveyor based on the number and size of the packages present on the feed conveyor. Information from the receiving conveyor and collector conveyor or singulator conveyor and /or sorting conveyor in a package handling system may also be utilized wherein the photo eyes data is used to measure the available area or space or volume on the conveyors to maintain a desired density of packages on selected conveyors). The conveyor speed is controlled as a function of occupancy on a collector or just prior to a slide sorter conveyor, singulator, or receiver conveyor.

The range sensing parcel flow management system 5 comprises or consists of a section 10 of a conveyor system wherein a plurality of photo eyess 20 detect parcels upon the primary or main conveyor collector conveyor which incorporate at least one feed conveyor 11 and one receiving conveyor 13 used in conjunction with a singulator 8, hold-and-release conveyor, accumulator, and/or strip conveyor typically downstream from the feed conveyor 11 which are shown in linear alignment with a singulator 8. The conveyors utilize roller and/or belts and each unit is powered by at least one independent motor to convey, arrange, and separate parcels at selected rates activation or of speed based upon desired occupancy of one or more selected conveyors. Thus, the degree of occupancy can be controlled on each conveyor independently of an adjacent conveyor upstream or downstream and the plurality of conveyors in the conveying system can be started, stopped, or the speed can be increased or decreased in order to increase the area of occupancy for a particular conveyor. The conveyor system section 10 utilizes independent motor driven conveyor zones.

The conveyor system section 10 includes at least one feed conveyor 11 and a downstream receiving conveyor 13. The selected inline feed conveyor speed is set to achieve a desired conveyor area utilization on the selected down stream receiving conveyor 13. A photo eye 21 is utilized to present a field of view of the feed conveyor occupancy zone 15 established for a given velocity V2 of parcels fed to the receiving conveyor occupancy defined zone 17 as the parcels are conveyed toward a concentrated desired occupancy zone 19 at a selected position after the transition section, zone, or point 70 where the feed conveyor 11 and receiving conveyor 13 merge.

More particularly, as shown in Figure 6, a plurality of photo eyess are shown focusing upon the selected transition section 70 of the conveying system section 10. The photo eyes 21 is focused upon the feeding conveyer occupancy defined zone 15 and receiving conveyer occupancy defined zone 17 providing a field of view at a portion of the conveying system where the parcels move from the feed conveyor 11 such as a collecting conveyor 12 or other downstream conveyor to the receiving conveyor 13.

Downstream photo eyess 22 and 23 focus on downstream occupancy zones at other transition points 72 and 73 respectively within the conveyor system 5. The rate of speed of individual conveyors is set to achieve a desired conveyor area utilization in a concentrated desired occupancy zone. A photo eye 20 is capable of measuring the occupancy over more than one zone. As illustrated in

Figure 4, occupancy of both the a skewed roller section 16 of the conveyor is measured as well as a recirculating belt section 14.

Figure 8 illustrates a side transfer feed conveyor 31 conveying article 66 intersects the flow through collection conveyor 12 at a 90 degree angle. Of course, the intersect angle is a matter of choice and may at any angle up to 90 degrees. The side feed conveyor 31 is shown feeding an article 67 onto the receiving or collecting conveyor 12, wherein the speed of the side feeder conveyor 31 is controlled to achieve desired conveyor area utilization on the receiving collection conveyor 12. The speed of the conveyors 12 and 31 is determined by the photo eyes measurement at a selected location 65 which includes both the feeding conveyor occupancy defined zone 15 and the receiving collector conveyor occupancy defined zone 17 prior to merging of the conveyors at transition point 73 wherein the desired occupancy zone 19 after the merger has an increased density in the selected area after the merge of the articles .

The range sensing photo eye parcel flow management system 5 is applicable to a bulk feed system from the point of unloading of articles from trailers onto induction conveyors through the separation and sorting process. As shown in Figure 9, articles unloaded from a truck 33 are of loaded from any one of a plurality of unloading induction conveyors 44, 46, 47, 48, and 50 whereby the rate of speed of the conveyers 44, 46, 47, 48, and 50 and the collection conveyor 12 are regulated by photo eyess 26, 27, 28, and 29 providing a photo eyes field of view at the merger or respective transition points 73, 74, 75, 76, and 77 of the induction feed conveyors 44, 46, 47, 48, and 50 and a collector conveyor 12. The collector belt 12 may be devoted to off-loading induction conveyors or flow from other sources such as a recirculating conveyor 14 from a sorter area due to output lanes which are frill. The induction feed conveyors) 44, 46, 47, 48, and 50 are regulated as a function of collector conveyor 12 speed and percent of occupancy of articles on the collector conveyor 12. An accumulating conveyor or accumulator 35 may be positioned up stream of the singulator 8 and down stream from the collector conveyor 12 and utilized as a receiving conveyor. The movement of the feed and/or collector conveyors may be regulated as a function of the accumulator conveyor 35 just prior to the singulator and is based on the area of the conveyor occupied with packages in order to provide a smooth feed to the singulator 8. A downstream singulator 8 includes a singulator photo eyes 32 providing a field of view 319 of articles on the singulator 8 and a photo eyes 41 providing a field of view 329 of the articles merging at transition point 78 with the singulator 8 fed from the adjacent accumulator conveyor 35.

A computer or microprocessor control system 500 controlling the vision based bulk parcel flow management system regulates a plurality of individual inputs based on the singulator fullness. The conveyor speeds of the feed conveyors 11, induction conveyors 44, 46, 47, 48, and 50 , collector conveyors 12, recirculating conveyor 14, singulator 8, and accumulator 35 are controlled and regulated as a function of the singulator fullness and incoming percent occupancy.

The range sensing photo eye vision control system includes at least a pair of opposing smart photo eye modules 20 capable of processing range sensing data and determine the distance across the conveyor within defined zones which can be adjusted for each photo eyes by zooming in or out or by selecting a particular grid or area on a smart device to determine the optimum conveyor speed. The smart photo eyes modules process range sensing data and determine occupancy percentage within the defined zones. A photo eyes IP address is designated for each photo eyes 20. For instance, the photo eyes can be programmed or set up so that a simple“right click” defines the photo eyes IP address. An ethemet system provides means for transmitting a signal to a computer via a command PC, PLDC, or VLC control system for calculating percent of occupancy information and calculating the desired conveyor speeds. Interface is accomplished via smart phone, tablet, laptop, smart watch, stand alone terminal and/or network. The configuration software provides a convenient interface to configure control zones and input control parameters. Individual photo eyes IP addresses are assigned to each photo eyes in the vision system.

The vision based bulk parcel flow management system includes means to open a configuration window to define“oversight” parameter and define zones where occupancy is to be measured at any time for any photo eyes occupancy defined zone. Figure 10 shows an oversight configuration window showing the receiving conveyor occupancy zone and feeding conveyor occupancy zone, each one of which can be resized and dragged together or independently moved to a different position or overlapping. A set of photo eyes for a particular transition point is selected and is utilized to present a field of view of a feed conveyor occupancy zone 15 and the receiving conveyor occupancy zone 17 to determine the conveyor area utilization and article count. The occupancy zone 15 of the feed conveyor can be resized in accordance with the parameter selected on the computer, smart phone or tablet screen by simply adjusting the size of the area on the screen. Furthermore, the receiving conveyor occupancy zone can be dragged and resized in the same manner. The occupancy rate will be calculated upon the selected areas accordingly to achieve the highest density of articles on the conveyor. The photo eyes aare utilized to present a field of view of the feed conveyor occupancy zone 15 established for a given velocity V2 of articles fed to the singulator conveyor pursuant to the occupancy defined in zone 17 which is typically at a transition point but can be any region or zone of a selected conveyor or article processing site. The photo eyes based vision system 5 recognizes the belt area utilization and article count. The vision system photo eyess 20 are usually positioned at flow entry points of the collector conveyor(s) 12 and at the singulator 8. The control algorithm requires recognition of individual items and the rate at which individual objects are passing, and the area utilization of the collector belt. Average article size and shape can be considered as well. The photo eyes and computer based conveyor package management system includes photo eyes monitoring the number and size of the packages present on the infeed conveyors, collector conveyor, singulator conveyor and sorting conveyor in a package handling system wherein the photo eyes data is used to measure the available area or space on the conveyors to maintain a desired density of packages on selected conveyor(s). It is even possible to trace and/or trace individual articles by their labels, code, or physical characteristics from the receipt of the article from the unloading truck and unloading dock to the point of the distribution vehicle.

Example 1

As shown in Figure 11 packages are offloaded from a cargo carrier onto a selected induction feed conveyor 44, 46, 47, 48, and 50 in flow communication with a collector conveyor 12 composed of modular units of sections of conveyor 120 - 134. For example, induction feed conveyor 50 intersects with and feeds articles onto collector conveyor section 121, induction feed conveyor 48 intersects with and feeds articles onto collector conveyor section 124, induction feed conveyor 47 intersects with and feeds articles onto collector conveyor section 127, feed conveyor 46 intersects with and feeds articles onto conveyor section 129, and feed conveyor 44 intersects with and feeds articles onto collector conveyor section 132.

The recycling or recirculating conveyor 14 intersects with and feeds into conveyor section 134.

In accordance with Figure 12, the collecting conveyor 12 starts at the first feed conveyor 50 and extending to an accumulator 35 and/or singulator 8 intersecting a selected number of inductor feed conveyors 44, 46, 47, 48, and 50. The recycle conveyor 14 also feeds articles onto the accumulator 35 or other conveyor intersecting with the collecting conveyor 12 prior to the singulator conveyor 8. The inductor feed conveyors include a selected number of modules or sections. For examples as shown sections 502, 504, 506, 508, 510, and 512 are sections of the inductor feed conveyors which include at least one transition point wherein the selected inductor feed conveyor speed is set to achieve a desired conveyor area utilization on the selected down stream receiving conveyor 13 Photo eyess 20, 21, 22, 23, and 24 are utilized to present a field of view of the inductor feed conveyor occupancy zone 15 established for a given velocity V2 of parcels fed to the receiving conveyor occupancy defined zone 17 as the parcels are conveyed toward a concentrated desired occupancy zone 19 at a selected position after the transition section, zone, or point 200, 210, 220, 230, and 240 respectively, where the inductor feed conveyor and receiving collector conveyor 12 merge. Feed conveyors 44, 46, 47, 48, and 50 also include modules or conveyor sections having designated motors which operate independently to decrease or increase the density of the articles on a collection conveyor 12.

Each of the conveyors or sections of a conveyor are driven by a separate variable speed motor.

This allows speeding up and slowing down of the individual sections of conveyor 50 to allow packages to be spaced out or concentrated in a given area in a desirable way depending upon the optimum flow rate for processing by the accumulator 35 or singulator 8. For instance, when a large gap 90 is detected between two particular packages, the rate of speed of the sections of conveyor between the packages are increased in order to close the gap between the packages. As best shown in Figures 13-16, articles on a feed conveyor intersects with a collector conveyor to illustrate sequentially how a package 89 is inserted from a feed conveyor 11 onto a receiving/collecting conveyor 12 containing a plurality of packages 81-88 inserting a package 89 into a gap 90 between other packages on the moving collector conveyor 12. As illustrated in Figure 17, a plurality of packages 91 are conveyed on a collector conveyor 12. A angled feed conveyor 92 and a perpendicular side feed conveyor 93 each carrying a parcel 89 intersects with the collector conveyor 12 whereby the speed of both of the feed conveyors 92 and 93 are controlled to insert the parcel 89 into gaps formed between the preexisting parcels 91 on the collector conveyor 12.

The range sensing photo eye parcel flow management system includes a plurality of feed conveyors induction feed conveyors in line or angled at up to 90 degrees to the receiving conveyor, an optional recirculating conveyor 14, an optional accumulator, sorting lanes, and a a singulator conveyor 8. Video photo eyess monitor the feed conveyors just before they merge onto the collector belt 12 at their respective monitor areas 200-250. Another video photo eyes 32 monitors the area 319 which includes the singulator conveyor 8. Photo eyess 26, 27, 28, 29, 30, and 32 monitor selected sections of conveyor 12 which lie before the areas where the infeed conveyors merge with the collector conveyor 12. Electrical cabinet 51 contains a video computer 500 which receives video input data from photo eyess 20-25 and 32. Electrical cabinet 52 contains speed controllers for the motors for all of the conveyors 44-50. The video computer is capable of counting individual packages and calculating the size“area” of packages as well based on information coming from the various photo eyess monitoring the conveyors. Singulator conveyor 8 receives randomly dispersed packages and aligns them in single file with respect to the movement of the conveyor. An example of a singulator conveyor is described in U.S. Patent 5,701,989 and PCT/US 14/00200 filed on October 21, 2014 and U.S. Serial No. 14/121,829 filed on October 21, 2014 all of which are incorporated by reference herein in its entirety.

The singulator conveyor 8 receives packages and articles such as bags or envelopes, parcels, boxes, luggage, mail, or other goods form the up stream conveyor 12. After the singulator conveyor 8, the individual packages are sorted and sent to a recirculating conveyor 14. The recirculating conveyor 14 conveys packages which have been removed during the alignment process back to a selected receiving conveyor collector conveyor 12 to be re-sorted on the singulator. The primary objective of the present invention is to keep the singulator conveyor 8 fully supplied with a steady flow of packages without jamming the packages accumulating on the collector conveyor 12 due to surges and slugs of packages received from up stream feed conveyors.

The singulator conveyor system is capable of handling random sized packages. Preferably, packages on the feed conveyors are single file; however, it is not uncommon for the packages to be irregularly spaced and oriented in random directions as they are offloaded from the bucks onto a selected feed conveyor 44, 46, 47, 48, and 50. The unloading usually occurs in slugs wherein a large volume of packages are of loaded in a short period of time. For instance, as best illustrated in Figure 12, photo eye 30 monitor areas convey the occupancy zones for conveyor sections 122 and 123. If the packages in the area are of a low density in occupancy zone area 210 as monitored by photo eyes 21, the digital image data (pixels) is processed by the controller and computer controls conveyor 48 to start, stop, slow or increase feed rate of the packages onto a collector conveyor section 124.

The packages are conveyed down stream toward conveyor section 35 and are monitored via photo eyess 26, 27, 28, 29, 30, and 31 as the packages move through the transition sections between the conveyors and through subsequent photo eyes occupancy zones, the computer program analyzes the overall loading of conveyor sections on a pixel by pixel basis. A package in a particular occupancy zone area is monitored by the photo eyes and a digital image of the size of the foot print of the package is ascertained by the video computer 500. The computer determines if the maximize the area of the conveyor in accordance with the feed rate and downstream load. The video based package management system will utilize the area of the entire conveyor assembly to control the flow of packages to the singulator, separator, scanner or processing site. The conveyor speed is controlled as a function of occupancy on a collector or just prior to a singulator. The computer feeds the information to the conveyor speed controllers to introduce packages from one or more feed conveyors to a collection conveyor wherein packages are detected by one or more photo eyess. The speed of selected conveyors is controlled for arrangement of the packages at optimal spacing maximizing the density of the packages on a conveyor and throughput of the system and accordingly minimizing the number of conveyors required for the system. When the computer determines there is a enough space on one of the conveyor belts, for example, the collector belt 12, the computer signals the controller to add a package 89 or packages by causing a feed belt 11 to add the package 89 or packages to the space 90 or vacant area on the collector belt 12.

When the density of the packages decreases at the transition zone between a feed conveyor and the collector conveyor 12, gaps are formed between packages resulting in increasing the rate of speed of a selected feed conveyor in order to maintain a desired flow rate of packages to the collector to maximize throughput of the singulator. This control scheme gives priority any selected conveyor. For instance, priority may be given to the first feed conveyors at the beginning of the collector conveyor 12 where the collector conveyor 12 will tend to be empty or have a less dense loading. Therefore, packages on the first feed conveyors will typically have more free area. Selected sections of collector conveyor 12 can be slowed down or even stopped to allow the latter feed conveyors to unload, as may be desired. Moreover, the collector conveyor 12 may be slowed or stopped to force more packages from the feed conveyor to push additional articles onto the collector conveyor 12 so that the area of the collector conveyor is full.

The package flow management control system 5 maximizes throughput of packages to a singulator conveyor and a sorting system, utilizing the greatest amount of area on the collector conveyor 12 or accumulator prior to the singulator 8. Other conveyors in the conveyor system are controlled based on the maximum capacity of the singulator determined at a constant rate of speed rather than an average of surge capacities. The increased efficiency enables the system to to minimize the number of conveyors required and the area, width, and/or length of the conveyors in the system to achieve a desired throughput at maximum efficiency.

The video computer 500 utilizes a plurality of photo eyess to monitor the occupancy zones of selected areas on the conveyors leading up to singulator or separation process. The computer compares the amount of free space on the selected conveyors and compares it to the the size of the package on the feed conveyor. If there is a adequate space, the feed conveyor will transfer the package. The amount of room required by a given package is determined by the programmer. For instance, the program may required that the amount of space on the collector conveyor is 1.5 or even 2 times the footprint of a given package depending on the orientation of the adjacent articles. Rate of speed changes of various conveyors are also controlled by the video computer to keep the singulator conveyor fully supplied. The computer send speed control signals to the speed controllers of all the conveyor sections to regulate throughput of packages.

The foregoing detailed description is given primarily for clearness of understanding and no unnecessary limitations are to be understood therefrom, for modification will become obvious to those skilled in the art upon reading this disclosure and may be made without departing from the spirit of the invention and scope of the appended claims. Accordingly, this invention is not intended to be limited by the specific exemplification presented herein above. Rather, what is intended to be covered is within the spirit and scope of the appended claims.

Claims

CLAIMS We claim:

1. A method of managing bulk parcel flow with a range sensing photo eye management system, comprising the steps of:

selecting a transition zone between a feed conveyor and a receiving conveyor each one having independent drive means;

selecting a photo eyes field of view of the selected transition zone;

determining a percentage of said feeding conveyor occupancy defined zone;

determining a percentage of said receiving conveyor occupancy defined zone;

selecting a percentage of a desired occupancy of said receiving conveyor after a merger of said parcels from said feeding conveyor to said receiving conveyor; and

feeding said parcels from said feed conveyor at a selected rate of speed to said receiving conveyor occupancy defined zone; and

merging said parcels at said conveyor area of said transition section between said feed conveyor and said receiving conveyor.

2. A range sensing photo eye based bulk parcel flow management system, comprising:

a feed conveyor and a receiving conveyor each one having independent drive motors;

a transition zone between said feed conveyor and said receiving conveyor;

a photo eye field of view of said selected transition zone;

said feeding conveyor having a selected occupancy defined zone;

said receiving conveyor having a selected occupancy defined zone; and

a computer for controlling said conveyor speed and movement based upon signals received from said photo eyes identifying gaps between packages on said receiving conveyor of sufficient space for insertion of an additional package from said feeding conveyor.

3. A method of managing bulk package conveyor flow with a range sensing photo eye management system, comprising the steps of:

selecting a photo eyes field of view of said selected transition zone;

setting a speed or movement of said feed conveyor, said receiving conveyor, or both said feed conveyor and said receiving conveyor to achieve a desired conveyor area utilization on a down stream receiving conveyor;

determining a percentage of said feed conveyor occupancy defined zone;

determining a percentage of said receiving conveyor occupancy defined zone;

selecting a conveyor area including a desired occupancy zone at a selected position;

feeding said packages from said feed conveyor to said receiving conveyor occupancy defined zone at a selected rate; and

merging said packages at said conveyor area of said transition section between said feed conveyor and said receiving conveyor.

4. The method of managing bulk package conveyor flow with a range sensing photo eye management system of claim 3 further comprising the steps of monitoring and controlling speed and movement of said feed conveyor and said receiver conveyor with a computer based upon signals received from said photo eyes identifying a gap between packages on said receiving conveyor of sufficient space for insertion of an additional package from said feeding conveyor.

5. The method of managing bulk conveyor package flow with a range sensing photo eye management system of claim 3 including the step of providing multiple photo eyess to monitor selected positions of said conveyor flow.

6. The method of managing bulk package conveyor flow with a range sensing photo eye management system of claim 5 including the step of providing an IP address to each photo eyes.

7. The method of managing bulk package conveyor flow with a range sensing photo eye management system of claim 3, including the step of setting a speed or movement of said feed conveyor, said receiving conveyor, or both said feed conveyor and said receiving conveyor as a function of occupancy on a collector.

8. The method of managing bulk package conveyor flow with a range sensing photo eye management system of claim 3, including the step of setting a speed or movement of said feed conveyor, said receiving conveyor, or both said feed conveyor and said receiving conveyor as a function of occupancy just prior to conveyance of said packages onto a singulator.

9. A range sensing photo eye based bulk package conveyor flow management system, comprising:

a feed conveyor and a receiving conveyor each one having independent drive means;

said feed conveyor having a selected occupancy defined zone;

said receiving conveyor having a selected occupancy defined zone;

at least one pair of opposing photo eyes providing a selected field of view of said selected transition zone, a selected occupancy zone, or said selected transition zone and said selected occupancy zone;

said feed conveyor, said receiver conveyor, or both said feed conveyor and said receiver conveyor conveying at a selected speed or time to achieve a desired conveyor area occupancy on a down stream receiving conveyor wherein said occupancy comprises conveyor area, conveyor volume, or conveyor density);

said selected transition section including a percentage of the desired occupancy of said receiving conveyor after the merger of said packages from said feed conveyor to said receiving conveyor; and a computer for controlling said conveyor speed and movement based upon signals received from said photo eyess identifying gaps between said packages on said receiving conveyor of sufficient space for insertion of an additional package from said feeding conveyor.

10. The range sensing photo eye based bulk package conveyor flow management system of claim

9 wherein said conveyor area comprises a collector.

11. The range sensing photo eye based bulk package conveyor flow management system of claim 9 wherein said conveyor area comprises a singulator for receiving and sorting packages.

12. A range sensing photo eye parcel conveyor flow management system comprising:

a feed conveyor in flow communication with an in-line receiving conveyor;

a transition zone selected on said feed conveyor;

at least one set of range sensing photo eye article detection device having a field of view of said transition zone;

a multiplexed light screen mounted on a frame in visual communication to said off-loading feed conveyor to detect the full length of said articles, a photocell mounted to a frame in visual communication with a conveyor surface to detect a portions of an article that rest on said conveyor; and

controller means for maintaining said feed conveyor speed to achieve a desired feed conveyor speed.

13. The range sensing photo eye parcel conveyor flow management system of claim 1 wherein said data from at least one article detecting device comprising at least one pair of opposing range sensing photo eyes, at least one camera, at least one video camera, at least one pixel detecting device, at least one digital imaging device, and combinations thereof in electrical communication with a receiving conveyor, a collector conveyor, a singulator conveyor, a sorting conveyor and combinations thereof is in communication with said computer for measuring a conveyor area, a conveyor space, a conveyor volume and combinations thereof for maintaining a desired occupancy (volume, area, or density) of articles on a selected conveyor.

14. The range sensing photo eye parcel conveyor flow management system of claim 1 wherein conveyor speed or velocity is controlled as a function of occupancy (volume, area, or density) on a selected conveyor just prior to said slide sorter, said collector conveyor, said singulator conveyor, said receiving conveyor with a control algorithm to recognize incoming flow occupancy (volume, area, or density), in terms of both belt utilization and throughput rate to control said article input flow.

15. The range sensing photo eye parcel conveyor flow management system of claim 1, wherein at least one pair of opposing range sensing photo eyes, at least one camera, at least one pixel detecting device, at least one digital imaging device, and combinations thereof is positioned at an input point of said receiving conveyor, said collector conveyor, said singulator conveyor, said sorting conveyor and combinations thereof.